Fitted bed sheet and method for making same

ABSTRACT

A fitted bed sheet includes a sheet body comprised of a blend of cotton and polyester and a bias binding comprised of a blend of cotton, polyester and at least one elastic material.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 60/713,817 filed Sep. 2, 2005, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to fitted bed sheets, and more particularly to fitted bed sheets having a sheet body made from a blend of cotton and polyester and a bias binding around the edge of the sheet body including an elastic material.

BACKGROUND OF THE INVENTION

Fitted bed sheets have been used in hospitals, nursing homes, and other healthcare facilities for many years. These sheets are often made from knitted materials, such as cotton, polyester or a blend thereof. Fitted bed sheets also typically include a bias binding, a narrow strip of material that is used to bind the edges of a sheet. The bias binding is typically made from knitted materials such as cotton, polyester or a blend thereof. These materials provide a sheet which can be easily fitted onto standard mattress sizes. The bias binding, in particular, helps to hold the fitted bed sheet around the sides and ends of the mattress.

Recently, hospitals and healthcare facilities have begun receiving complaints that their mattress sizes do not cater to larger patients. In response to these complaints, mattress manufacturers began manufacturing mattresses that are larger in size than standard mattresses. These larger mattresses may be up to several inches longer than standard mattresses. Additionally, some of the larger mattress sizes may be about nine to ten inches in depth and, in some cases, up to about twelve inches in depth, compared to about six inches for standard mattresses. Some mattresses even have thicker portions near the head region, i.e., about nine inches in depth, and/or thinner portions near the foot region, i.e., about three inches in depth, such that the mattress dimensions vary depending on the region of the mattress. Thus, current versions of fitted bed sheets do not easily fit these types of non-standard mattress sizes.

To address the change in mattress sizes, some sheet manufacturers have increased the length of their sheet products, including fitted bed sheets. However, these larger fitted bed sheets do not adequately fit the standard mattress sizes. As a result, the larger fitted bed sheets may bunch up on one end or side of the bed and cause some inconvenience or discomfort to the patient. Furthermore, it may take longer to change fitted bed sheets that do not fit properly as more time will be spent adjusting the fitted bed sheets to fit the bed. Some hospitals now purchase multiple sizes of fitted bed sheets in order to deal with these problems.

In order to avoid having to purchase and use several different sizes of fitted bed sheets, it is desirable to have fitted bed sheets made from typical knitted materials such as cotton, polyester, or blends thereof that can conform to many different mattress sizes. In particular, it is desirable to have fitted bed sheets made of cotton, polyester or a blend thereof that have an elastic material in the bias binding. The elastic material allows the bias binding to have more flexibility in order to fit a wider range of mattress sizes. Such fitted bed sheets will also fit mattresses that have portions that are thicker and/or thinner than standard mattress sizes. The better fit provides a smoother surface for a patient which, in turn, provides for better skin care. The addition of an elastic material also adds to the durability of the bias binding and, therefore, decreases the number of new sheets that may need to be purchased by a hospital or healthcare facility each year. Furthermore, while it is possible to manufacture fitted bed sheets that contain an elastic material in both the body of the sheet and the bias binding, it is less costly and more desirable to manufacture sheets having an elastic material only in the bias binding.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a fitted bed sheet includes a sheet body having a top portion, a pair of opposing side portions and a pair of opposing end portions. The opposing side portions and the opposing end portions are joined together and extend from the top portion to a bias binding continuously attached along a periphery of lower edges of the opposing side portions and the opposing end portions. The top portion, the opposing side portions and the opposing end portions are comprised of a blend of cotton and polyester materials and the bias binding is comprised of a blend of cotton, polyester and at least one elastic material.

In another aspect of the present invention, a method for making a fitted bed sheet includes the steps of providing a sheet body having a top portion, opposing side portions and opposing end portions that are comprised of a blend of cotton and polyester materials. The method includes joining the opposing side portions and opposing end portions. The opposing side portions and opposing end portions extend from the top portion to lower edges of the opposing side portions and opposing end portions. The method further includes continuously attaching a bias binding along an entire periphery of the lower edges of the opposing side portions and the opposing end portions. The bias binding comprises a blend of cotton, polyester and at least one elastic material.

In an alternative aspect of the present invention, a fitted bed sheet comprises a sheet body and a bias binding attached to the sheet binding. The sheet body is comprised of a knitted material having a blended yarn comprised of about 50% by weight to about 60% by weight cotton and about 40% by weight to about 50% by weight polyester. The bias binding is comprised of a first yarn comprised of cotton and polyester and a second yarn comprised of an elastic material. The first yarn and the second yarn are knitted together to form a blend of about 50% by weight to about 60% by weight cotton, about 38% by weight to about 48% by weight polyester and about 2% by weight to about 10% by weight of the elastic material.

In a further alternative aspect of the present invention, a method of making a fitted bed sheet includes knitting a sheet body comprised of a blended yarn comprising about 50% by weight to about 60% by weight cotton and about 40% by weight to about 50% by weight polyester. The method also includes knitting together a first yarn and a second yarn to form a bias binding. The first yarn is comprised of cotton and polyester and the second yarn is comprised of an elastic material. The bias binding is comprised of a blend of about 50% by weight to about 60% by weight cotton, about 38% by weight to about 48% by weight polyester and about 2% by weight to about 10% by weight of the elastic material. The method further includes attaching the bias binding to the sheet body to form the fitted bed sheet.

The above summary of the present invention is not intended to represent each embodiment or every aspect of the present invention. The detailed description and Figures will describe many of the embodiments and aspects of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings.

FIG. 1 shows a perspective view of a fitted bed sheet placed onto a mattress according to one embodiment of the present invention.

FIG. 2 shows a perspective view of the underside of a mattress and the bias binding of a fitted bed sheet according to one embodiment of the present invention.

While the invention is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The present invention is directed to a fitted bed sheet 10 as shown in FIG. 1. The fitted bed sheet 10 is adapted to fit over the top of a mattress 20 and extend around the sides and ends of the mattress 20. As shown in FIG. 1, the mattress 20 with the fitted bed sheet 10 may typically be placed on top of another mattress or box spring 22. In this arrangement, part of the fitted bed sheet 10 is located between the mattress 20 and the other mattress or box spring 22.

The fitted bed sheet 10 includes a sheet body 12 that has a top portion 14 and a pair of opposing side portions 16 and opposing end portions 18. The opposing side portions 16 and opposing end portions 18 extend from the top portion 14 and are joined together by stitching or other suitable means of attachment. The fitted bed sheet 10 is adapted to fit over the top of the mattress 20, and the opposing side portions 16 and opposing end portions 18 are adapted to fit over the sides and ends of the mattress 20, respectively, and to extend around to the bottom, or underside, of the mattress 24 as shown in FIG. 2.

In FIG. 2, the opposing side portions 16 and opposing end portions 18 of the fitted bed sheet 10 extend over at least a portion of the bottom of the mattress 24 and terminate with a bias binding 30 that is continuously attached along a periphery of the lower edges 32 of the opposing side portions 16 and opposing end portions 18. The bias binding 30 is a strip of material that binds the lower edges 32 of the fitted bed sheet 10. The bias binding 30 helps to keep the fitted bed sheet 10 contoured to the shape of the mattress 20. The bias binding 30 is attached along the periphery of the lower edges 32 by stitching or any other suitable means of attachment. In some embodiments, the bias binding 30 may be attached along only certain portions of the periphery of the lower edges 32.

The fitted bed sheet 10 may be manufactured from different types of materials that are comfortable to a user and that are adapted to keep the fitted bed sheet 10 attached to the mattress 20. For example, the sheet body 12, including the top portion 14, opposing side portions 16 and opposing end portions 18, may be comprised of knitted materials such as cotton, polyester, or a blended yarn comprising cotton and polyester.

According to one embodiment of the present invention, the amount of cotton in the sheet body 12, including the top portion 14, opposing side portions 16 and opposing end portions 18, may range from about 50% to about 60% by weight. According to another embodiment, the amount of cotton ranges from about 52% to about 58% by weight. According to a further embodiment, the amount of cotton is about 55% by weight.

Similarly, the amount of polyester in the sheet body 12, including the top portion 14, opposing side portions 16 and opposing end portions 18, may range from about 40% to about 50% by weight. According to another embodiment, the amount of polyester ranges from about 42% to about 48% by weight. According to a further embodiment, the amount of polyester is about 45% by weight.

The weight percentage of cotton and polyester may be selected based on a variety of factors that provide desirable performance characteristics to the fitted bed sheet 10 such as softness, breathability, durability, drying characteristics, etc. The weight percentage of cotton and polyester may also be selected based on cost considerations. Cotton and polyester materials that may be used with the present invention are commercially available from numerous suppliers worldwide.

As discussed above, in order to accommodate larger mattress sizes and mattresses with dimensions that vary with the region of the mattress, i.e., thinner or thicker head regions and/or foot regions, sheet manufacturers have begun to manufacture larger fitted bed sheets. However, the larger fitted bed sheets may cause problems for hospitals and health care facilities that still employ standard mattress sizes. Fitting the standard mattresses with larger fitted bed sheets increases the time that health care workers must spend changing patients' beds because extra time is needed to adjust the larger fitted bed sheets to the standard mattress sizes. Problems such as bunching and sliding of the fitted bed sheets can occur when using the larger fitted bed sheets on standard mattress sizes if the fitted bed sheets do not fit properly. Furthermore, fitted bed sheets that do not fit properly do not provide a smooth surface for a patient to lay or sit on which increases the possibility of skin care problems.

In order to overcome these problems and to assist in providing fitted bed sheets that fit multiple mattress sizes and dimensions, the present invention includes at least one elastic material in the bias binding 30 of the fitted bed sheet 10. The at least one elastic material provides flexibility and allows the fitted bed sheet 10 to be fitted around the top, sides and ends of different mattress sizes and dimensions without “popping” off. The elastic material in the bias binding 30, thus, enhances the fit of the fitted bed sheet 10 and allows the fitted bed sheet 10 to better contour to the shape of the mattress. The addition of an elastic material also adds to the durability of the bias binding 30 because the bias binding 30 is less likely to become stretched out beyond its recovery point.

Thus, according to at least one embodiment of the present invention, the bias binding 30 includes at least one elastic material. The at least one elastic material may include spandex, such as Lycra®, or any other suitable elastic material. Suitable elastic materials may include elastic materials that do not crack or break after repeated use. Lycra® is commercially available from E. I. du Pont de Nemours and Company in Wilmington, Del.

The bias binding 30 may be formed by knitting together a first yarn made of a knitted or woven material, such as a blend of cotton and polyester, and a second yarn made of at least one elastic material. The ratio of the first yarn to the second yarn may include a ratio of about 1:1. A description of the process of knitting the first and second yarns into a knitted fabric is included in U.S. Pat. No. 6,164,092, assigned to Medline Industries, Inc., and which is hereby incorporated by reference in its entirety.

According to one embodiment of the present invention, the bias binding 30 includes from about 50% to about 60% by weight cotton, from about 38% to about 48% by weight polyester and from about 2% to about 10% by weight of an elastic material, such as spandex. According to another embodiment, the bias binding 30 includes about 52% to about 58% by weight cotton, from about 41% to about 45% by weight polyester and from about 2% to about 7% by weight of an elastic material, such as spandex. According to a further embodiment, the bias binding 30 is comprised of about 54% by weight cotton, about 43% by weight polyester and about 3% by weight of an elastic material, such as spandex. The weight percentage of the at least one elastic material may be selected based on a variety of factors such as cost considerations and desired performance characteristics of the bias binding, such as the ability to stretch and cover multiple mattress sizes.

According to one embodiment, to form the fitted bed sheet 10, the sheet body is formed by knitting a blended yarn comprised of about 50% by weight to about 60% by weight cotton and about 40% by weight to about 50% by weight polyester. The bias binding 30 is then attached to the sheet body 12 as described herein. The bias binding is formed by knitting together a first yarn strand comprised of cotton and polyester and a second yarn strand comprised of an elastic material. The bias binding comprises a blend of about 50% by weight to about 60% by weight cotton, about 38% by weight to about 48% by weight polyester and about 2% by weight to about 10% by weight of an elastic material.

Examples of fitted bed sheets that may be used with the embodiments of the present invention include the Soft-Fit® Knitted Fitted Contour Sheet and the Soft-Span 150™ Knitted Fitted Contour Sheet as manufactured by Medline Industries, Inc. in Mundelein, Ill. The embodiments of the present invention are not limited to the specific fitted bed sheets recited above or use in connection with the fitted bed sheets recited above. Other fitted bed sheets may be manufactured according to the embodiments of the present invention.

According to alternative embodiment A, a fitted bed sheet comprises a sheet body having a top portion, a pair of opposing side portions and a pair of opposing end portions. The opposing side portions and the opposing end portions being joined together and extending from the top portion to a bias binding continuously attached along a periphery of lower edges of the opposing side portions and the opposing end portions. The top portion, the opposing side portions and the opposing end portions are comprised of a blend of cotton and polyester materials and the bias binding is comprised of a blend of cotton, polyester and at least one elastic material.

According to alternative embodiment B, the fitted bed sheet according to alternative embodiment A, wherein the elastic material is spandex.

According to alternative embodiment C, the fitted bed sheet according to alternative embodiment A, wherein the top portion, the opposing side portions and the opposing end portions are comprised of from about 50% by weight to about 60% by weight cotton and from about 40% by weight to about 50% by weight polyester.

According to alternative embodiment D, the fitted bed sheet according to alternative embodiment A, wherein the top portion, the opposing side portions and the opposing end portions are comprised of from about 52% by weight to about 58% by weight cotton and from about 42% by weight to about 48% by weight polyester.

According to alternative embodiment E, the fitted bed sheet according to alternative embodiment A, wherein the top portion, the opposing side portions and the opposing end portions are comprised of about 55% by weight cotton and about 45% by weight polyester.

According to alternative embodiment F, the fitted bed sheet according to alternative embodiment A, wherein the bias binding is comprised of from about 50% by weight to about 60% by weight cotton, from about 38% by weight to about 48% by weight polyester and from about 2% by weight to about 10% by weight spandex.

According to alternative embodiment G, the fitted bed sheet according to alternative embodiment A, wherein the bias binding is comprised of from about 52% by weight to about 58% by weight cotton, from about 41% by weight to about 45% by weight polyester and from about 2% by weight to about 7% by weight spandex.

According to alternative embodiment H, the fitted bed sheet according to alternative embodiment A, wherein the bias binding is comprised of about 54% by weight cotton, about 43% by weight polyester and about 3% by weight spandex.

According to alternative embodiment I, a method of making a fitted bed sheet, comprises the steps of providing a sheet body having a top portion, opposing side portions and opposing end portions that are comprised of a blend of cotton and polyester materials; joining the opposing side portions and opposing end portions, the opposing side portions and opposing end portions extending from the top portion to lower edges of the opposing side portions and opposing end portions; and continuously attaching a bias binding along an entire periphery of the lower edges of the opposing side portions and the opposing end portions, the bias binding comprising a blend of cotton, polyester and at least one elastic material.

According to alternative embodiment J, the method according to alternative embodiment I, wherein the elastic material is spandex.

According to alternative embodiment K, the method according to alternative embodiment I, wherein the top portion, the opposing side portions and the opposing end portions are comprised of from about 50% by weight to about 60% by weight cotton and from about 40% by weight to about 50% by weight polyester.

According to alternative embodiment L, the method according to alternative embodiment I, wherein the top portion, the opposing side portions and the opposing end portions are comprised of from about 52% by weight to about 58% by weight cotton and from about 42% by weight to about 48% by weight polyester.

According to alternative embodiment M, the method according to alternative embodiment I, wherein the top portion, the opposing side portions and the opposing end portions are comprised of about 55% by weight cotton and about 45% by weight polyester.

According to alternative embodiment N, the method according to alternative embodiment I, wherein the bias binding is comprised of from about 50% by weight to about 60% by weight cotton, from about 38% by weight to about 48% by weight polyester and from about % by weight 2% to about 10% by weight spandex.

According to alternative embodiment 0, the method according to alternative embodiment I, wherein the bias binding is comprised of from about 52% by weight to about 58% by weight cotton, from about 41% by weight to about 45% by weight polyester and from about 2% by weight to about 7% by weight spandex.

According to alternative embodiment P, the method according to alternative embodiment I, wherein the bias binding is comprised of about 54% by weight cotton, about 43% by weight polyester and about 3% by weight spandex.

According to alternative embodiment Q, a fitted bed sheet comprises a sheet body comprised of a knitted material having a blended yarn comprised of about 50% by weight to about 60% by weight cotton and about 40% by weight to about 50% by weight polyester and a bias binding attached to the sheet body. The bias binding is comprised of a first yarn comprised of cotton and polyester and a second yarn comprised of an elastic material. The first yarn strand and the second yarn strand are knitted together to form a blend of about 50% by weight to about 60% by weight cotton, about 38% by weight to about 48% by weight polyester and about 2% by weight to about 10% by weight of the elastic material.

According to alternative embodiment R, a method of making a fitted bed sheet comprises knitting a sheet body comprised of a blended yarn comprising about 50% by weight to about 60% by weight cotton and about 40% by weight to about 50% by weight polyester; knitting together a first yarn and a second yarn to form a bias binding, the first yarn comprised of cotton and polyester and the second yarn comprised of an elastic material, the bias binding comprising a blend of about 50% by weight to about 60% by weight cotton, about 38% by weight to about 48% by weight polyester and about 2% by weight to about 10% by weight of the elastic material; and attaching the bias binding to the sheet body to form the fitted bed sheet.

While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the invention, which is set forth in the following claims. 

1. A fitted bed sheet, comprising: a sheet body having a top portion, a pair of opposing side portions and a pair of opposing end portions, the opposing side portions and the opposing end portions being joined together and extending from the top portion to a bias binding continuously attached along a periphery of lower edges of the opposing side portions and the opposing end portions, wherein the top portion, the opposing side portions and the opposing end portions are comprised of a blend of cotton and polyester materials and the bias binding is comprised of a blend of cotton, polyester and at least one elastic material.
 2. The fitted bed sheet according to claim 1, wherein the elastic material is spandex.
 3. The fitted bed sheet according to claim 1, wherein the top portion, the opposing side portions and the opposing end portions are comprised of from about 50% by weight to about 60% by weight cotton and from about 40% by weight to about 50% by weight polyester.
 4. The fitted bed sheet according to claim 1, wherein the top portion, the opposing side portions and the opposing end portions are comprised of from about 52% by weight to about 58% by weight cotton and from about 42% by weight to about 48% by weight polyester.
 5. The fitted bed sheet according to claim 1, wherein the top portion, the opposing side portions and the opposing end portions are comprised of about 55% by weight cotton and about 45% by weight polyester.
 6. The fitted bed sheet according to claim 1, wherein the bias binding is comprised of from about 50% by weight to about 60% by weight cotton, from about 38% by weight to about 48% by weight polyester and from about 2% by weight to about 10% by weight spandex.
 7. The fitted bed sheet according to claim 1, wherein the bias binding is comprised of from about 52% by weight to about 58% by weight cotton, from about 41% by weight to about 45% by weight polyester and from about 2% by weight to about 7% by weight spandex.
 8. The fitted bed sheet according to claim 1, wherein the bias binding is comprised of about 54% by weight cotton, about 43% by weight polyester and about 3% by weight spandex.
 9. A method of making a fitted bed sheet, comprising the steps of: providing a sheet body having a top portion, a pair of opposing side portions and a pair of opposing end portions that are comprised of a blend of cotton and polyester materials; joining the opposing side portions and opposing end portions, the opposing side portions and opposing end portions extending from the top portion to lower edges of the opposing side portions and opposing end portions; and continuously attaching a bias binding along an entire periphery of the lower edges of the opposing side portions and the opposing end portions, the bias binding comprising a blend of cotton, polyester and at least one elastic material.
 10. The method according to claim 9, wherein the elastic material is spandex.
 11. The method according to claim 9, wherein the top portion, the opposing side portions and the opposing end portions are comprised of from about 50% by weight to about 60% by weight cotton and from about 40% by weight to about 50% by weight polyester.
 12. The method according to claim 9, wherein the top portion, the opposing side portions and the opposing end portions are comprised of from about 52% by weight to about 58% by weight cotton and from about 42% by weight to about 48% by weight polyester.
 13. The method according to claim 9, wherein the top portion, the opposing side portions and the opposing end portions are comprised of about 55% by weight cotton and about 45% by weight polyester.
 14. The method according to claim 9, wherein the bias binding is comprised of from about 50% by weight to about 60% by weight cotton, from about 38% by weight to about 48% by weight polyester and from about 2% by weight to about 10% by weight spandex.
 15. The method according to claim 9, wherein the bias binding is comprised of from about 52% by weight to about 58% by weight cotton, from about 41% by weight to about 45% by weight polyester and from about 2% by weight to about 7% by weight spandex.
 16. The method according to claim 9, wherein the bias binding is comprised of about 54% by weight cotton, about 43% by weight polyester and about 3% by weight spandex.
 17. A fitted bed sheet, comprising: a sheet body comprised of a knitted material having a blended yarn comprised of about 50% by weight to about 60% by weight cotton and about 40% by weight to about 50% by weight polyester; a bias binding attached to the sheet body, the bias binding comprised of a first yarn comprised of cotton and polyester and a second yarn comprised of an elastic material, wherein the first yarn and the second yarn are knitted together to form a blend of about 50% by weight to about 60% by weight cotton, about 38% by weight to about 48% by weight polyester and about 2% by weight to about 10% by weight of the elastic material.
 18. The fitted bed sheet according to claim 17, wherein the sheet body is comprised of about 55% by weight cotton and about 45% by weight polyester and the bias binding is comprised of about 54% by weight cotton, about 43% by weight polyester and about 3% by weight of the elastic material.
 19. A method of making a fitted bed sheet, comprising: knitting a sheet body comprised of a blended yarn comprising about 50% by weight to about 60% by weight cotton and about 40% by weight to about 50% by weight polyester; knitting together a first yarn and a second yarn to form a bias binding, the first yarn comprised of cotton and polyester and the second yarn comprised of an elastic material, the bias binding comprising a blend of about 50% by weight to about 60% by weight cotton, about 38% by weight to about 48% by weight polyester and about 2% by weight to about 10% by weight of the elastic material; and attaching the bias binding to the sheet body to form the fitted bed sheet.
 20. The method of claim 19, wherein the fitted bed sheet comprises a sheet body comprising about 55% by weight cotton and about 45% by weight polyester and a bias binding comprising about. 54% by weight cotton, about 43% by weight polyester and about 3% by weight of the elastic material. 